CASE 821F XR Wheel Loader Service Repair Manual Instant Download

1
821F 921F Stage IV Wheel Loader SERVICE MANUAL
Part number 47969425 English November 2015
2015 CNH Industrial Italia S.p.A. All Rights
Reserved.
2
SERVICE MANUAL 821F XR 821F ZBAR 921F XR 921F
ZBAR
47969425_EN 29/01/2016
EN
3
Link Product / Engine
Product Market Product Engine
821F XR WHEEL LOADER TIER 4B Europe F4HFE613SB004
821F ZBAR WHEEL LOADER TIER 4B Europe F4HFE613SB004
921F XR WHEEL LOADER TIER 4B Europe F4HFE613RB006
921F ZBAR WHEEL LOADER TIER 4B Europe F4HFE613RB006
47969425_EN 29/01/2016
4
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Contents INTRODUCTION Engine.....................
..................................................
................ 10 10.001 Engine and
crankcase . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 10.1 10.202 Air
cleaners and lines . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
10.2 10.500 Selective Catalytic Reduction (SCR)
exhaust treatment . . . . . . . . . . . . . . . .
. . . . . . . . . . . 10.3 10.400 Engine
cooling system . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
10.4 10.414 Fan and drive . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 10.5 10.310 Aftercooler. . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
10.6 10.304 Engine lubrication system . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10.7 Transmission...........................
..................................................
. 21 21.113 Powershift transmission . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 21.1 21.155 Powershift transmission
internal components. . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
21.2 21.700 Torque converter . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 21.3 Four-Wheel Drive (4WD)
system ...........................................
....... 23 23.314 Drive shaft. . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 23.1 Front axle
system ...........................................
............................ 25 25.100 Powered
front axle . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
25.1 25.102 Front bevel gear set and
differential . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 25.2 25.108 Final drive hub, steering
knuckles, and shafts . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
25.3 Rear axle system.............................
...........................................
27 27.100 Powered rear axle. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 27.1 27.106 Rear bevel gear set and
differential . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 27.2 27.120 Planetary and final
drives . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 27.3 Brakes and controls
..................................................
.................. 33 33.202 Hydraulic service
brakes . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 33.1 33.110 Parking
brake or parking lock . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 33.2
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Hydraulic systems.................................
......................................
35 35.000 Hydraulic systems. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . 35.1 35.300 Reservoir, cooler, and
filters. . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 35.2 35.106 Variable
displacement pump . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . 35.3 35.357 Pilot
system . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 35.4 35.752 Hydraulic fan drive cooling
system. . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . 35.5 35.355 Hydraulic hand control . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 35.6 35.724 Front loader
hydraulic system control . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 35.7 35.701 Front loader arm
hydraulic system . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 35.8 35.723 Front loader bucket
hydraulic system . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 35.9 35.734 Tool quick coupler
hydraulic system . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . 35.10 Frames and ballasting
..................................................
............... 39 39.100 Frame . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
39.1 Steering.....................................
................................................
41 41.101 Steering control . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . 41.1 41.200 Hydraulic control
components. . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 41.2 41.216 Cylinders . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . .
41.3 41.910 Auxiliary steering . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 41.4 Wheels.....................
..................................................
............... 44 44.511 Front wheels. . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 44.1 44.520
Rear wheels . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . 44.2 Cab climate control ...................
..................................................
50 50.200 Air conditioning. . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 50.1 Electrical
systems...........................................
............................ 55 55.100
Harnesses and connectors. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . .
55.1 55.301 Alternator. . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . 55.2 55.302 Battery. .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. 55.3
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55.011 Fuel tank system . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . 55.4 55.988 Selective Catalytic
Reduction (SCR) electrical system . . . . . . . .
. . . . . . . . . . . . . . . . . . . .
55.5 55.989 Exhaust Gas Recirculation (EGR)
electrical system . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . 55.6 55.012
Engine cooling system . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
55.7 55.519 Cab brake controls . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . 55.8 55.030 Service brake
electrical system . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 55.9 55.031 Parking brake
electrical system . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . 55.10 55.512 Cab controls. .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
55.11 55.051 Cab Heating, Ventilation, and
Air-Conditioning (HVAC) controls. . . . . . . . .
. . . . . . . . 55.12 55.050 Heating,
Ventilation, and Air-Conditioning (HVAC) control
system. . . . . . . . . . . . . . . 55.13
55.047 Steering control system . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
55.14 55.530 Camera. . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . 55.15 55.518 Wiper and
washer system. . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 55.16 55.514 Cab
lighting . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
55.17 55.408 Warning indicators, alarms, and
instruments . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 55.18 55.DTC
FAULT CODES . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . .
55.19 Front loader and bucket.....................
..........................................
82 82.300 Bucket . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . 82.1 Platform, cab,
bodywork, and decals .............................
................ 90 90.150 Cab . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . .
90.1 90.156 Cab glazing . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 90.2 90.114 Operator
protections . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . 90.3
47969425_EN 29/01/2016
8
INTRODUCTION
47969425_EN 29/01/2016 1
9
INTRODUCTION
Safety rules
Personal safety This is the safety alert
symbol. It is used to alert you to potential
personal injury hazards. Obey all safety
messages that follow this symbol to avoid
possible death or injury.
Throughout this manual you will find the signal
words DANGER, WARNING, and CAUTION followed by
special in- structions. These precautions are
intended for the personal safety of you and those
working with you. Read and understand all the
safety messages in this manual before you operate
or service the machine.
DANGER indicates a hazardous situation that, if
not avoided, will result in death or serious
injury. WARNING indicates a hazardous situation
that, if not avoided, could result in death or
serious injury. CAUTION indicates a hazardous
situation that, if not avoided, could result in
minor or moderate injury.
FAILURE TO FOLLOW DANGER, WARNING, AND CAUTION
MESSAGES COULD RESULT IN DEATH OR SERIOUS
INJURY. Machine safety NOTICE Notice indicates
a situation that, if not avoided, could result in
machine or property damage. Throughout this
manual you will find the signal word Notice
followed by special instructions to prevent
machine or property damage. The word Notice is
used to address practices not related to personal
safety. Information NOTE Note indicates
additional information that clarifies steps,
procedures, or other information in this
manual. Throughout this manual you will find the
word Note followed by additional information
about a step, procedure, or other information in
the manual. The word Note is not intended to
address personal safety or property damage.
47969425_EN 29/01/2016 3
10
INTRODUCTION Personal safety Carefully read
this Manual before proceeding with main-
tenance, repairs, refuelling or other machine
operations. Repairs have to be carried out only
by authorized and in- structed staff specific
precautions have to be taken when grinding,
welding or when using mallets or heavy ham-
mers. Non-authorized persons are not allowed to
repair or carry out maintenance on this machine.
Do not carry out any work on the equipment
without prior authorization. Ask your employer
about the safety instructions in force and
safety equipment.
TULI12WEX2004AA 1
Nobody should be allowed in the cab during
machine maintenance unless he is a qualified
operator helping with the maintenance work. If
it is necessary to move the equipment to carry
out re- pairs or maintenance, do not lift or
lower the equipment from any other position than
the operators seat. Never carry out any
operation on the machine when the engine is
running, except when specifically
indicated. Stop the engine and ensure that all
pressure is relieved from hydraulic circuits
before removing caps, covers, valves, etc. All
repair and maintenance operations should be
carried out with the greatest care and
attention. Service stairs and platforms used in a
workshop or in the field should be built in
compliance with the safety rules in force.
TULI12WEX2005AA 2
Any functional disorders, especially those
affecting the safety of the machine, should
therefore be rectified im- mediately. DANGER Unex
pected movement! Make sure parking brake is
applied. Secure machine with wheel
chocks. Failure to comply will result in death or
serious injury. D0013A
Before performing any work on the machine, attach
a maintenance in progress tag. This tag can be
applied on the left-hand control lever, safety
lever or cab door.
47969425_EN 29/01/2016 4
11
INTRODUCTION
Product identification
LEIL15WHL0056FA 1

1. Bucket
2. Loader lift arms (Z-bar version)
3. Driving lights
4. Roll Over Protection System (ROPS) cab
5. Precleaner

1. Engine and Selective Catalyst Reduction (SCR)
   system
2. Counterweight
3. Electric master switch and battery jump post
   (optional)
4. Steps

47969425_EN 29/01/2016 24
12
INTRODUCTION
LEIL13WHL0214FA 2

1. Diesel Exhaust Fluid (DEF) fill tank
2. Sliding access panel
3. Fuse access door
4. Cab air filter

1. Bucket cylinder
2. Front frame
3. Rear frame
4. Steps

47969425_EN 29/01/2016 25
13
SERVICE MANUAL Engine 821F XR 821F ZBAR 921F
XR 921F ZBAR
47969425_EN 29/01/2016 10
14
Engine - Engine and crankcase
Engine - General specification
Engine with 4 Speed Transmission
A. Low idle 870 RPM to 930 RPM
Alternate low idle 670 RPM to 730 RPM
Alternate Accelerated Idle 1270 RPM to 1330 RPM
B. Maximum No Load RPM 2065 RPM to 2185 RPM
C. Converter Stall 1855 RPM to 2055 RPM
D. Hydraulic Stall 2065 RPM to 2265 RPM
E. Converter Hydraulic Stall 1550 RPM to 1750 RPM
Temperature of the torque converter oil 82 - 104 C (180 - 219 F)
Temperature of the hydraulic oil 54 - 57 C (129 - 135 F)
Engine with 5 Speed Transmission
A. Low idle 870 RPM to 930 RPM
Alternate low idle 670 RPM to 730 RPM
Alternate Accelerated Idle 1270 RPM to 1330 RPM
B. Maximum No Load RPM 2065 RPM to 2185 RPM
C. Converter Stall 1912 RPM to 2112 RPM
D. Hydraulic Stall 2070 RPM to 2270 RPM
E. Converter Hydraulic Stall 1590 RPM to 1790 RPM
Temperature of the torque converter oil 82 - 104 C (180 - 219 F)
Temperature of the hydraulic oil 54 - 57 C (129 - 135 F)
NOTE Hydraulic Stall and Converter Hydraulic
Stall RPM values are read while the lift arms are
rising with the bucket held rolled back and the
engine at Wide Open Throttle (WOT) in max power
mode with transmission in manual mode and in 3rd
gear.
Engine - General specification
Engine with 4 Speed Transmission
A. Low idle 870 RPM to 930 RPM
Alternate low idle 670 RPM to 730 RPM
Alternate Accelerated Idle 1270 RPM to 1330 RPM
B. Maximum No Load RPM 2115 RPM to 2200 RPM
C. Converter Stall 1835 RPM to 2035 RPM
D. Hydraulic Stall 2075 RPM to 2275 RPM
E. Converter Hydraulic Stall 1560 RPM to 1760 RPM
Temperature of the torque converter oil 82 - 104 C (180 - 219 F)
Temperature of the hydraulic oil 54 - 57 C (129 - 135 F)
Engine with 5 Speed Transmission
A. Low idle 870 RPM to 930 RPM
Alternate low idle 670 RPM to 730 RPM
Alternate Accelerated Idle 2170 RPM to 1330 RPM
B. Maximum No Load RPM 2115 RPM to 2200 RPM
C. Converter Stall 1837 RPM to 2037 RPM
D. Hydraulic Stall 2127 RPM to 2327 RPM
E. Converter Hydraulic Stall 1560 RPM to 1760 RPM
Temperature of the torque converter oil 82 - 104 C (180 - 219 F)
Temperature of the hydraulic oil 54 - 57 C (129 - 135 F)
NOTE Hydraulic Stall and Converter Hydraulic
Stall RPM values are read while the lift arms are
rising with the bucket held rolled back and the
engine at Wide Open Throttle (WOT) in max power
mode with transmission in manual mode and in 3rd
gear.
47969425_EN 29/01/2016 10.1 10.001 / 3
15
Engine - Engine and crankcase Engine - General
specification Engine Service Manual The table
below lists the part numbers of the Engine FPT
F4HFE613 Service Manual. The part numbers of the
Eu- ropean languages related to this manual are
reported. See the Engine Service Manual for more
details about the engine overhaul.
Language Engine Service Manual P/N
English 47606122
French 47606125
German 47606126
Italian 47606127
Spanish 47606130
47969425_EN 29/01/2016 10.1 10.001 / 4
16
Engine - Engine and crankcase Engine -
Remove NOTE Emissions sensors mounted in the
exhaust stream are sensitive to extreme
vibrations. Use of tools that gen- erate extreme
vibrations, such as impact wrenches and hammers,
will result in damage to emission sensors. Avoid
using these tools during any service procedure in
close proximity of emission sensors. If the use
of these tools cannot be avoided, remove the
sensors using extreme caution prior to performing
any service procedure. 1. Park machine on a level
surface and lower the bucket to the ground. Put
articulation lock in LOCKED position and stop
the engine.
RCPH10WHL063BAL 1
2. Actuate the brake pedal several times to
discharge brake accumulators.
RCPH10WHL435AAH 2
3. Put key switch in ON position. Pilot control
switch must be in the ON position and then move
loader control lever(s) back and forth at least
30 times to release any pressure from hydraulic
circuit. Put key switch in OFF position.
RCPH10WHL119BAL 3
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17
Engine - Engine and crankcase
4. Raise grill located above the cooler box just
behind the cab. Then slowly loosen the hydraulic
reservoir filler cap to release pressure in the
reservoir.
RCPH10WHL099BAL 4
5. Locate the master and hood raise switch by
the battery box. Then raise the hood and put the
master discon- nect switch in the OFF position.
RCPH10WHL106AAH 5
6. Unhook the rubber T-handle (1) and raise the
upper panel (2). Make sure that the security
levers are blocked.
LEIL13WHL0137AB 6
7. Raise both side panels (1). Then remove the
thumb screws (2) and inner fender panels
(3). NOTE right-hand side of the machine is
shown. The op- eration is similar for the left
side.
LEIL13WHL0612AB 7
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18
Engine - Engine and crankcase
8. Place a suitable container below radiator
drain, remove radiator cap and coolant drain
plug (arrow) to drain en- gine coolant. Then
reinstall drain plug and radiator cap after
coolant has drained. NOTE See machine
specifications for cooling system vol- ume.
RCPH10WHL054BAL 8
9. Place a suitable container below engine oil
drain. Re- move drain plug and drain oil into
container. Then re- install drain plug. NOTE
See machine specifications for engine oil sump
vol- ume.
RCPH10WHL054BAL 9
10. After oil drains, disconnect drain hose from
frame by removing jam nut (1). Then pull hose
from frame in preparation for engine removal. (2)
RAPH12WEL0598AA 10
11. Double up a nylon lifting strap and slide
through the exhaust stack (1) on the hood.
LEIL13WHL0552AB 11
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19
Engine - Engine and crankcase
12. Place a bar or pipe through the strap loop
inside the hood and attach the strap to a
suitable lifting device. Then raise the hood
with the strap to release tension on the lifting
motor.
RAPH12WEL0600AA 12
13. Tag and disconnect the rearview camera wire
harness (if machine is equipped with a rearview
camera).
RAPH12WEL0601AA 13
14. Cut wire ties and remove rearview camera wire
har- ness from hood. Then place it off to the
side in a safe location. (If machine is equipped
with a rearview cam- era.)
LEIL13WHL0140AB 14
15. Remove hood wire harness clamp (1) from the
cooler housing. Then tag and remove the hood
ground wire (2) from cooler housing.
LEIL13WHL0149AB 15
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Engine - Engine and crankcase
16. Tag and disconnect hood wiring harness
connector (1) from rear chassis wiring harness
connector. Remove hood wire harness clamp (2)
from the fan shroud.
LEIL13WHL0150AB 16
17. Have another person to balance the hood and
LOOSEN the hood hinge mounting bolts (arrows)
from the cooler frame. NOTE Do not remove the
hood hinge mounting bolts at this time.
LEIL13WHL0142AB 17
18. Remove the pin from the bottom of the lifting
motor cylinder where it attaches to the loader
frame.
RAPH12WEL0606AA 18
19. Put the master disconnect switch in the ON
position. Then, retract the lifting motor
cylinder (2), replace pin and disconnect wiring
harness (1).
RAPH12WEL0062AA 19
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21
Engine - Engine and crankcase
20. Put master disconnect switch (1) in OFF
position. Re- move the battery cover and
disconnect ground lead from the batteries (2).
You may replace battery cover if desired to give
you a place to stand.
RAPH12WEL0608AA 20
21. Have another person to balance the hood and
re- move the hood hinge mounting bolts (arrows)
from the cooler frame.
LEIL13WHL0142AB 21
22. Carefully raise and remove hood from loader.
Lower hood onto suitable platform and disconnect
lifting equipment from exhaust stack (1) . NOTE
Radiator overflow hose may interfere with left
hand hood hinge movement and hood removal.
LEIL13WHL0552AB 22
23. Tag and disconnect engine wiring harness
connector from air filter restriction switch.
RAPH12WEL0610AA 23
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Engine - Engine and crankcase
24. Tag and disconnect engine wiring harness
connector from air inlet humidity sensor (1).
LEIL13WHL0143AB 24
25. Loosen clamp (1) on the crankcase ventilation
hose (2) and disconnect hose.
LEIL13WHL0144AB 25
26. Loosen clamps on turbocharger and air filter
hous- ing. Then remove the intake air hose (1) .
Cover tur- bocharger inlet to prevent debris
entry.
LEIL13WHL0145AB 26
27. Loosen the clamp from the elbow connected to
the turbocharger.
LEIL14WHL0203AB 27
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Engine - Engine and crankcase
28. Loosen the clamp on the hose at the after
cooler inlet and remove the tube.
LEIL13WHL0147AB 28
29. Loosen clamp on the air inlet hose at the air
filter hous- ing.
LEIL13WHL0148AB 29
30. Loosen the clamp (1) on the air inlet hose
(2) at the exhaust support bracket. Remove the
air inlet hose (2).
LEIL13WHL0151AB 30
31. Remove the four bolts securing the air filter
housing to the mounting support bracket. Then
remove the air filter housing.
LEIL13WHL0153AB 31
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Engine - Engine and crankcase
32. Remove the four mounting bolts from the belt
cover. Then remove the cover. NOTE After
removing the belt cover, remove the cover
mounting bracket from the left rear side of
machine frame.
LEIL13WHL0154AB 32
33. Remove the drive belt from the engine.
LEIL13WHL0155AB 33
34. If machine is equipped with the air
conditioning sys- tem, identify, tag, and
disconnect the engine wiring harness connectors
from air compressor clutch con- nector (1) and
high pressure switch (2). Then remove the three
mounting bolts (3) for the compressor and
carefully set it on the left battery cover.
LEIL13WHL0156AB 34
35. Tag and disconnect the wiring from the
alternator.
RAPH12WEL0622AA 35
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Engine - Engine and crankcase
36. Remove the return line of the SCR coolant.
RAPH12WEL0623AA 36
37. Tag and remove the wires from the starter
solenoid (1), the ground cable (2), and ground
strap (3) from the starter. NOTE Move the
starter cables away from the engine.
RAPH12WEL0624AA 37
38. Remove the bolts securing the wiring harness
clamps to the engine.
RAPH12WEL0625AA 38
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26
Engine - Engine and crankcase 39. Remove the
ground wires from the engine. NOTE Move the
wiring harness away from the engine.
RAPH12WEL0625AA 39
40. If the machine is so equipped, unplug the
engine block heater and set it aside.
LEIL15WHL0016AB 40
41. Loosen the clamp (see the arrow in figure)
and dis- connect the pipe.
LEIL15WHL0015AB 41
42. Loosen the clamps and remove the lower
coolant hose from the engine.
RAPH12WEL0629AA 42
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Engine - Engine and crankcase
43. Remove the radiator hose from the engine.
LEIL13WHL0159AB 43
44. Remove the return radiator hose (1) and the
engine coolant vent hose from the top of the
radiator.
LEIL13WHL0141AB 44
45. Remove the overflow tank of the engine
coolant.
RAPH12WEL0633AA 45
46. Remove the bracket of the overflow tank.
RAPH12WEL0634AA 46
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Engine - Engine and crankcase
47. Remove the cooling fan screen.
LEIL13WHL0160AB 47
48. Loosen the clamp (1) on the intake manifold
for the output hose of the after cooler. Loosen
the clamp (2) from the body of the DEF/ADBLUE
tank vent filter.
LEIL13WHL0613AA 48
49. Loosen the clamp on the after cooler, and
remove the output hose of the after cooler from
the machine.
LEIL13WHL0162AB 49
50. Tag and disconnect the fuel filter heater
wire (1) and the water sensor (2). Then drain
fuel filter and discon- nect the inlet (3) and
outlet (4) fuel lines from the fuel filter head.
Plug the lines and cap the fittings. Remove the
ground wire and the attachment bolt (5) of the
fuel filter head.
LEIL13WHL0163AB 50
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29
Engine - Engine and crankcase 51. Tag and
remove the grid heater cable (1). NOTE Hold the
rear nut with a second wrench to prevent grid
heater damage.
LEIL13WHL0164AB 51
52. Remove wire harness support clamp.
RAPH12WEL0064AA 52
53. Remove the P-clamp and cut the cable ties by
the sup- ply module. Disconnect the end of the
jumper harness (near the supply module) from the
DOC support.
LEIL15WHL0034AB 53
54. Tag and disconnect the NOx controller harness
(1), the NH3 sensor connector (4) and the
temperature sensor connector (5) . Then remove
the screws (2) and (3) of the clamp.
LEIL13WHL0165AB 54
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Engine - Engine and crankcase
55. Loosen the clamp (1) on the Diesel Oxidation
Catalyst (DOC).
LEIL13WHL0166AB 55
56. Tag and disconnect the connector (1).
LEIL13WHL0167AB 56
57. Tag and disconnect the wire harness of the
tempera- ture sensor (1) for the Selective
Catalytic Reduction muffler (SCR) and cut the
connector wire clamps. Loosen the screws and
remove the bar (2).
LEIL14WHL0213AB 57
58. Attach a suitable lifting straps to the
Selective Cat- alytic Reduction (SCR) muffler
support structure. Re- move the bolts securing
the support structure at the front (1) and rear
(2) part of the structure. Use a suitable lifting
device and carefully lift the support structure
of the Selective Catalytic Reduction (SCR)
muffler from the machine. NOTE Pay particular
attention to the connection between the (SCR)
muffler and the Diesel Oxidation Catalyst (DOC).
LEIL13WHL0169AB 58
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Engine - Engine and crankcase
59. Tag and disconnect the wire harness from the
buzzer. Remove the bolts (1) securing the front
support struc- ture of the (SCR) muffler and
remove it.
LEIL13WHL0174AB 59
60. Tag and disconnect wire harness from primary
fuel filter.
RAPH12WEL0068AA 60
61. Remove DEF/ADBLUE storage tank cover located
on the right hand side of the machine.
LEIL13WHL0170AB 61
62. Tag and disconnect the wire harness and DEF/
ADBLUE supply and return lines from the
DEF/ADBLUE storage tank. Cap the supply lines.
RAPH12WEL0070AA 62
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Engine - Engine and crankcase
63. Remove the support bracket of the hood lift
cylinder.
RAPH12WEL0071AA 63
64. Remove the heater hose from the engine.
LEIL15WHL0009AB 64
65. Disconnect the main connector of the supply
module.
LEIL13WHL0171AB 65

• Attach suitable lifting straps to the support
  structure
• of the Diesel Oxidation Catalyst (DOC). The sup-
  ply module and the coolant control valve are also
  at- tached to this support structure.

LEIL14WHL0212AB 66
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Engine - Engine and crankcase
67. Loosen the two haxagonal nuts of the sensors
(3) and (4) and disconnect the sensors (3) and
(4). Loosen the clamp (1) on the Diesel Oxidation
Catalyst (DOC) and disconnect the exhaust pipe
(2) from the Diesel Oxidation Catalyst (DOC).
LEIL13WHL0229AA 67
68. Remove the SCR coolant supply line from the
engine.
LEIL15WHL0008AB 68
69. Remove the bolts that secure the support
structure of the Diesel Oxidation Catalyst
(DOC). Use a suitable lifting device and
carefully lift the sup- port structure of the
Diesel Oxidation Catalyst (DOC) (with SCR system
components attached) from the ma- chine.
LEIL13WHL0173AB 69
70. Disconnect the wiring harness from the EDC17
con- troller. NOTE Lifting up on the lever will
release the connector from the controller.
LEIL13WHL0175AB 70
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Engine - Engine and crankcase
71. Remove the fuel line from the top of the
primary fuel filter, plug the line and cap the
fitting. NOTE Make note on how fuel lines are
routed.
LEIL13WHL0176AB 71
72. Remove the support clamp of the fuel
line. NOTE Make note on how fuel lines are
routed.
LEIL13WHL0177AB 72
NOTE make note on how fuel lines are routed, for
reference during the reassembly.
LEIL15WHL0017FB 73
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Engine - Engine and crankcase
73. Remove the upper and lower covers for the
drive shaft.
RAPH12WEL0079AA 74
74. Remove the drive shaft bolts (1) from the
flywheel. Move the drive shaft clear of the
flywheel.
RAPH12WEL0080AA 75
75. Connect and turn on vacuum pump to hydraulic
reser- voir. Tag and remove the hydraulic lines
from the brake system pump (arrow), plug the
lines and cap the fittings.
LEIL13WHL0178AB 76
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36
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37
Engine - Engine and crankcase
76. Connect suitable lifting equipment to engine
lifting brackets. Take up all slack in lifting
equipment. Re- move the engine mounting bolts.
RAPH12WEL0080AA 77
LEIL15WHL0036AA 78
77. Slowly raise engine from rear chassis. Be
sure all wire harness connections and hoses have
been dis- connected and are clear of the engine.
Guide the oil drain hose from the frame as the
engine is lifted. Re- move engine from machine.
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38
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